Advance Optima AO2000 Series Continuous gas analyzers Models AO2020, AO2040. Measurement made easy. Modular continuous gas analyzers

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1 Data sheet 10/ EN Rev. 6 Advance Optima AO2000 Series Continuous gas analyzers Models AO2020, AO2040 Measurement made easy Modular continuous gas analyzers One central unit and various analyzer modules Common controls, common connection technology, common system housing Analyzer modules with different measurement principles for all process and emissions monitoring applications Multiple analyzer systems with up to four analyzer modules handling a total of six sample components Extensive automatic calibration with air or integral calibration cells eliminating the need for test gas cylinders Safety Concept for measuring flammable gases in Zone 2 and for measuring corrosive and toxic gases Simultaneous digital and analog display of measured values on a large graphics panel Menu-driven operator interface Clear-text status messages Multiple interfaces for communication with host and associated systems Flexibly configurable analog and digital inputs and outputs on various input/output modules Optional integrated pneumatics module Housing design for 19-inch rack mounting (Model AO2020) or wall mounting (Model AO2040) Modular design for ease of service Self-monitoring function indicates when maintenance is required

2 Modular analyzer product line Overview Advance Optima AO2000 Series is a line of modules used for continuous process gas analysis. The product line consists of the following modules: Analyzer modules Pneumatics module Electronics module I/O modules Housing with display and control unit System bus The modules can be arranged in various ways to form single or multiple analyzer systems. The electronics module, power supply and housing with display and control unit are also collectively referred to as the central unit. Analyzer modules Analyzer modules: Uras26 Infrared analyzer module Limas11 Process photometer analyzer module Magnos206 Oxygen analyzer module Magnos27 Oxygen analyzer module ZO23 Trace oxygen analyzer module Caldos25 Thermal conductivity analyzer module Caldos27 Thermal conductivity analyzer module Fidas24 FID analyzer module MultiFID14 FID analyzer module MultiFID14 NMHC FID analyzer module LS25 Laser analyzer module Each analyzer module consists of the sensor and associated electronics having its own processor. The analyzer modules are linked to the system controller via the system bus. The laser analyzer module is linked to the central unit via Ethernet. The analyzer modules are supplied with 24-VDC from an integral power supply or an external unit. The electrochemical oxygen sensor is available as an option in combination with an analyzer module. Pneumatics module The pneumatics module contains the following elements when fully equipped: One or three solenoids to control test gas supply One or two disposable elements for fine filtration One gas supply pump with coarse filter and capillary One or two flow monitors The pneumatics module is always associated with an analyzer module and installed in the same housing as the analyzer module. Electronics module, interfaces The electronics module incorporates the system controller with the I/O modules. The system controller carries out the following functions: Processing and communicating the measured values supplied by the analyzer module sensor electronics Compensating measured values, e.g. cross sensitivity correction Controlling system functions, e.g. calibration Display and control functions Controlling associated systems, e.g. gas supply Communicating with external systems The system controller communicates with the other functional units of the gas analyzer (e.g. the analyzer modules) via the system bus. Interfaces for controlling associated systems and for communicating with external systems are located on the system controller (Ethernet 10/100/1000BASE-T interface) and on the I/O modules. The I/O modules are attached and directly connected to the system controller board. There are various types of I/O modules: 2-way analog output modules have two analog outputs. 4-way analog output modules have four analog outputs. 4-way analog input modules have four analog inputs. Digital I/O modules have four digital inputs and four digital outputs. Modbus modules have one RS485 and one RS232 interface. Profibus modules have one RS485 and one MBP interface (not intrinsically safe). Examples of I/O module applications include: Output of measured values Output of status and alarm signals Calibration control Control of external solenoid valves and pumps Measurement range switching and feedback Feed of current or status signals from external analyzers Feed of status signals from peripherals Housing The housing is available as a 19-inch (model AO2020) or wallmount (model AO2040) unit with IP20 or IP54 protection. IP54 housing versions can be purged. The display and control unit is located on the front panel of the housing when the electronics module is installed. System bus The gas analyzer s functional units are interconnected via the system bus. The system bus structure is linear with a maximum length of 350 meters. Only one electronics module with up to five I/O modules should be connected to a system bus structure. Connection of sample gas conditioning modules The SCC-F sample gas feed unit and the SCC-C sample gas cooler can be connected to the gas analyzer via the system bus by means of an I/O board installed in the sample gas feed unit. Thus it is possible to display, monitor and control individual sample gas conditioning functions in the gas analyzer such as cooler temperature or condensate and flow status. For further information please refer to the System components and accessories for sample gas conditioning data sheet. 2 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

3 Configuration of analyzer units and multiple analyzer systems This data sheet contains specifications for all modules and components in the Advance Optima AO2000 Series modular product line. This data sheet was not intended to be used for configuring an analyzer unit or a multiple analyzer system. For a quotation please contact your ABB Analytical representative who can also provide advice and support. Example 1 shows the modules and components that normally make up an analyzer unit as well as the possibilities for configuring an analyzer unit. The modular product line allows modules and components to be formed into an analyzer unit (see example 1) or into multiple analyzer systems (see example 2). Example 1: Analyzer unit configuration (19-inch housing) Housing with display and control unit Housing with display and control unit (see page 37) Housing type with/without display and control unit Power supply (unless otherwise specified on electronics module) Analyzer module Housing Analyzer with display moduleand control unit + + = Electronics module Electronics module Pwr supply Pwr supply Electronics module (see page 38) Power supply I/O module equipment Interfaces Analyzer modules (see pages 4 to 33) Gas path design Gas connections Type of installation Analyzer-specific data System configuration Number of housings Number of analyzer modules System bus wiring 24-VDC analyzer power supply Example 2: Multiple analyzer system variant (wall-mount housings) Housing with display and control unit Housing without display and control unit Housing without display and control unit Analyzer module 1 Analyzer module 2 Pneumatics module Analyzer module 3 Power supply Electronics module Power supply Power supply System bus 10/ EN Rev. 6 Advance Optima AO2000 Series Data Sheet 3

4 Infrared analyzer module Uras26 Measurement principle Non-dispersive infrared absorption in the λ = 2.5 to 8 μm wavelength range Photometer to measure from 1 to 4 components with 1 or 2 beam paths and 1 or 2 receivers in each beam path Sample components and measurement ranges The Uras26 analyzer module has one physical measurement range per sample component. As an option, smaller measurement ranges can be electronically derived from the physical measurement range. The smallest range is measurement range 1. The smallest measurement ranges shown in the following table are based on the first sample component in beam path 1. Sample component Smallest class 1 range Smallest class 2 range Smallest class 2 range with calibration cell CO 0 50 ppm 0 10 ppm 0 50 ppm 2) A CO ppm 0 5 ppm 0 25 ppm 2) A NO 0 75 ppm 0 75 ppm 0 75 ppm 2) A SO ppm 0 25 ppm 0 25 ppm 2) A N 2 O 0 50 ppm 0 20 ppm 0 50 ppm 2) A CH ppm 0 50 ppm 0 50 ppm 2) A NH ppm 0 30 ppm B C 2 H ppm ppm ppm B C 2 H ppm ppm ppm B C 2 H ppm 0 50 ppm 0 50 ppm 2) B C 3 H ppm ppm ppm 2) B C 3 H ppm 0 50 ppm 0 50 ppm 2) B C 4 H ppm 0 50 ppm 0 50 ppm 2) B C 6 H ppm ppm ppm 2) B R 134a ppm 0 50 ppm 0 50 ppm 2) B SF ppm 0 4 ppm B H 2 O ppm ppm ppm C 1) See price information 2) The smallest measurement range 1 is shown. The largest measurement range should be at least four times larger. Gas group 1) Other sample components on request. Measurement range quantity 1 to 4 ranges per sample component Largest measurement range 0 to 100 vol.% or 0 vol.% to saturation or 0 vol.% to LEL Measurement ranges within ignition limits cannot be provided. Measurement range ratio 1:20 Measurement ranges with suppressed zero-point Electronic zero-point suppression or differential measurement based on a base level > 0 with flowing reference gas, max. suppression ratio of 1:10 Stability The following data apply to measurement range 1 in a delivered analyzer module. Linearity deviation 1 % of span Option: Linearization according to EPA specifications for automobile exhaust gas measurement Repeatability 0.5 % of span Zero drift 1 % of span per week; for ranges smaller than class 1 to class 2: 3 % of span per week Sensitivity drift 1 % of measured value per week Output fluctuation (2 σ) 0.2 % of span at electronic T90 time = 5 sec (class 1) or = 15 sec (class 2) Detection limit (4 σ) 0.4 % of span at electronic T90 time = 5 sec (class 1) or = 15 sec (class 2) Influence effects Flow effect Flow rate in the 20 to 100 l/h range: Within detection limits Associated gas effect/cross sensitivity The knowledge of the sample gas composition is necessary for the analyzer configuration. Selectivity measures to reduce associated gas effect (optional): Incorporation of interference filters or filter vessels, internal electronic cross-sensitivity correction or carrier gas correction for a sample component by other sample components measured with the Uras26. Temperature effect Ambient temperature in permissible range At zero-point: 1 % of span per 10 C; for ranges smaller than class 1 to class 2: 2 % of span per 10 C On sensitivity with temperature compensation: 3 % of measured value per 10 C On sensitivity with thermostat effect at 55 C (optional): 1 % of measured value per 10 C Air pressure effect At zero-point: No effect On sensitivity with pressure correction by means of integral pressure sensor: 0.2 % of measured value per 1 % air pressure change The pressure sensor is located in the sample gas path if hoses are used as the internal gas lines. If tubing is used for internal gas lines the pressure sensor is routed to the outside via a hose. Pressure sensor working range: p abs = 600 to 1250 hpa Power supply effect 24 VDC ± 5 %: 0.2 % of span 4 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

5 Infrared analyzer module Uras26 Dynamic response Warm-up time Approx. 30 minutes without thermostat; approx. 2 hours with thermostat 90% response time T 90 = 2.5 sec for measurement cell length = 200 mm and sample gas flow = 60 l/h without signal damping (low pass filter). Low-pass time constant adjustable from 0 to 60 sec. Calibration Zero-point calibration With inert gas, e.g. nitrogen, or with ambient air that is free of the sample component. End-point calibration With gas-filled calibration cells (optional) or with test gas mixtures. It is recommended to verify the calibration cell set values once a year. During calibration of a multi-component analyzer, possible cross-sensitivity and/or carrier gas corrections by internal or external measurement components are switched off. Therefore, corrected measurement components should be calibrated only using a test gas consisting of the measurement component and an inert gas like nitrogen. sample gas must not be explosive under normal conditions. If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation p e 100 hpa; in case of a sample gas supply failure the pressure must not exceed the maximum value p e = 500 hpa. The version with gas paths designed as stainless steel tubes should be selected and housing purge with nitrogen should be provided when measuring flammable gases and vapors. Before using the analyzer module the corrosion resistance against the specific sample gas must be checked. Version in category 3G see page 34 Gas connections The drawing below shows the gas connection arrangement in an exemplary manner for the three variants: A 1 gas path with 1 sample cell, B 1 gas path with 2 sample cells in series and C 2 separate gas paths with 1 sample cell each. The actual gas connection arrangement of an analyzer module is found in the analyzer data sheet for the delivered instrument. Materials in contact with the sample medium 10 1 Analyzer (sample cells) Tubing: Aluminum or gold-plated aluminum. Window: CaF 2, option: BaF 2. Connectors: Rust- and acid-resistant steel (SAE 316Ti) Gas lines and connectors FPM hoses and PTFE tubing with stainless steel connectors. Option: Rust- and acid-resistant steel tubes (SAE 316Ti) Sample gas inlet conditions Temperature The sample gas dew point should be at least 5 C below the ambient temperature throughout the sample gas path. Otherwise a sample gas cooler or condensate trap is required. Inlet pressure p e = 2 to 500 hpa Lower pressures require a sample gas pump and higher pressures require a pressure reducer. Outlet pressure Atmospheric pressure Flow rate 20 to 100 l/h Corrosive gases Highly corrosive associated gas components, e.g. chlorine (Cl 2 ) and hydrogen chloride (HCl), as well as gases or aerosols containing chlorine must be cooled or undergo prior absorption. Provide for housing purge. Flammable gases The analyzer module is suitable for measuring flammable gases and vapors under atmospheric conditions (p abs 1.1 bar, oxygen content 21 vol.%). Temperature class: T4. The 1 Pressure sensor for external pressure measurement 1) 2 3 Sample gas inlet A or B or C gas path 1 4 Sample gas outlet A or C gas path 1 5 Purge gas inlet housing 1) 6 Purge gas outlet housing 1) (also with flow sensor) 7 Sample gas inlet C gas path 2 1) 8 Sample gas outlet B or C gas path 2 1) 9 Reference gas inlet gas path 1 1) 10 Reference gas outlet gas path 1 1) Pneumatics module 1) : 11 Sample gas inlet A or B or C gas path 1 12 End point gas inlet (with 3 solenoids) or sample gas inlet C gas path 2 (only with flow sensor) 13 Test gas/zero-point gas inlet (with 1 or 3 solenoids) or sample gas outlet C gas path 2 (only with flow sensor) in this case connect with sample gas inlet 7 14 Sample gas outlet A or B or C gas path 1 connect with sample gas inlet 3 1) Option 10/ EN Rev. 6 Advance Optima AO2000 Series Data Sheet 5

6 Process photometer analyzer module Limas11 Measurement principle Gas filter correlation or wavelength comparison in ultraviolet and visible spectrum range λ = 200 to 600 nm (Limas11 UV) and in infrared spectrum range λ = 2.5 to 10 μm (Limas11 IR) Photometer to measure from 1 to 4 components Sample cells made from various materials are available for measuring in corrosive, toxic and flammable gases (see page 8) Sample components and measurement ranges The Limas11 analyzer module has one physical measurement range per sample component. As an option, smaller measurement ranges can be electronically derived from the physical measurement range. The smallest range is measurement range 1. Sample component Smallest class 1 range Smallest class 2 range Limas11 UV: NO 2) 0 50 ppm 0 10 ppm A SO ppm 0 25 ppm A NO ppm 0 50 ppm B NH ppm 0 30 ppm B H 2 S 0 50 ppm 0 25 ppm B Cl ppm ppm D CS ppm 0 50 ppm C COS ppm ppm C Limas11 IR: CO ppm ppm A CO ppm ppm A HCl ppm ppm D CH ppm ppm A C 2 H ppm ppm B C 2 H ppm ppm B C 2 H ppm ppm B C 3 H ppm ppm B C 3 H ppm ppm B C 4 H ppm ppm B Gas group 1) 1) See price information 2) The UV-RAS (ultra-violet resonant absorption spectroscopy) method is used to make the analyzer selective to the sample component NO. Other sample components on request. Measurement range quantity 1 to 4 ranges per sample component Largest measurement range 0 to 100 vol.% or 0 vol.% to saturation or 0 vol.% to LEL Measurement ranges within ignition limits cannot be provided. Measurement range ratio Measurement ranges freely adjustable within a range ratio of 1:20 relative to the factory-set reference measurement range. Measurement ranges with suppressed zero-point Electronic zero-point suppression, max. suppression ratio of 1:10 Stability The following data apply to measurement range 1 in a delivered analyzer module. Linearity deviation 1 % of span Option: Linearization acc. to EPA specifications for automotive exhaust gas measurement Repeatability 0.5 % of span Zero drift 2 % of span per week; for ranges smaller than class 1 to class 2: 1.5 % of span per day (Recommendation: daily automatic zero-point calibration) Sensitivity drift 1 % of measured value per week Output fluctuation (2 σ) Limas11 UV: 0.5 % of span at electronic T90 time = 10 sec; Limas11 IR: 0.5 % of span at electronic T90 time (static/ dynamic) = 60/5 sec; for ranges smaller than class 1 to class 2: 1 % of span Detection limit (4 σ) 1 % of span; for ranges smaller than class 1 to class 2: 2 % of span Influence effects Flow effect Flow rate in the 20 to 100 l/h range: Within detection limits Associated gas effect/cross sensitivity The knowledge of the sample gas composition is necessary for the analyzer configuration. Selectivity measures to reduce associated gas effect (optional): Incorporation of filters cells or internal electronic cross-sensitivity correction or carrier gas correction for a sample component by other sample components measured with the Limas11. Temperature effect Ambient temperature in permissible range, Sample cell thermostat control to +60 C At zero-point: 1 % of span per 10 C; for ranges smaller than class 1 to class 2: 2 % of span per 10 C On sensitivity: 1 % of measured value per 10 C Air pressure effect At zero-point: No effect On sensitivity with pressure correction by means of integral pressure sensor: 0.2 % of measured value per 1 % air pressure change The pressure sensor is located in the sample gas path if hoses are used as the internal gas lines. If tubing is used for internal gas lines the pressure sensor is routed to the outside via a hose. Pressure sensor working range: p abs = 600 to 1250 hpa Power supply effect 24 VDC ± 5 %: 0.2 % of span 6 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

7 Process photometer analyzer module Limas11 Dynamic response Warm-up time Approx. 2.5 hours 90% response time T 90 = 4 sec for measurement cell length = 262 mm and sample gas flow = 60 l/h without signal damping (low pass filter). Low-pass time constant adjustable from 0 to 60 sec Calibration Zero-point calibration With inert gas, e.g. nitrogen, or with ambient air that is free of the sample component End-point calibration With gas-filled calibration cells (optional) or with test gas. It is recommended to verify the calibration cell set values once a year. During calibration of a multi-component analyzer, possible cross-sensitivity and/or carrier gas corrections by internal or external measurement components are switched off. Therefore, corrected measurement components should be calibrated only using a test gas consisting of the measurement component and an inert gas like nitrogen. Sample gas inlet conditions Temperature The sample gas dew point should be at least 5 C below the ambient temperature throughout the sample gas path. Otherwise a sample gas cooler or condensate trap is required. Inlet pressure p e = 2 to 500 hpa (maximum pressure see page 8) Lower pressures require a sample gas pump and higher pressures require a pressure reducer. Outlet pressure Atmospheric pressure Flow rate 20 to 100 l/h Corrosive, toxic and flammable gases See page 8 Purge gas See page 8 Gas connections See page 9 Materials in contact with the sample medium See page 8 10/ EN Rev. 6 Advance Optima AO2000 Series Data Sheet 7

8 Process photometer analyzer module Limas11 Sample cells Standard cell Quartz cell Safety cell Application Standard applications Corrosive gases Corrosive, toxic and flammable gases Wavelength range 200 to nm 200 to 4000 nm CaF 2 window: 200 to nm SiO 2 window: 200 to 4000 nm Resistance 1) Suitable for measurement of Non-corrosive gases Corrosive gases, e.g. wet Cl 2, wet HCl, H 2 SO 4, SO 3, ozone Not suitable for measurement of Highly corrosive gases, e.g. Fluorine compounds gases containing chlorine, H 2 SO 4, SO 3, fluorine compounds Safety principle Toxic gases Housing purge ( 20 l/h) with sample component-free air or with N 2 Housing purge ( 20 l/h) with sample component-free air or with N 2 Corrosive gases, e.g. dry HCl, dry COCl 2 (< 50 ppm H 2 O) Wet gases containing chlorine, H 2 SO 4, SO 3, fluorine compounds Cell purge 2) with N 2 or with sample component-free air with negative pressure and flow monitoring; additional monitoring for sample gas traces possible Cell purge 2) with N 2 or with sample component-free air with excess pressure 3) and flow monitoring Cell purge 2) with N 2 Corrosive gases PTFE gas lines, housing purge ( 20 l/h) with sample component-free air or with N 2 Housing purge ( 20 l/h) with sample component-free air or with N 2 Flammable gases 4) Stainless steel gas lines, Housing purge ( 20 l/h) housing purge ( 20 l/h) with N 2 with N 2 Category 3G flammable gases Cell purge 2) with N 2 with excess pressure 3) and flow monitoring Seal integrity < 1 x 10 3 hpa l/s < 1 x 10 6 hpa l/s < 1 x 10 6 hpa l/s Pressure rating Continuous p e < 500 hpa p e < 500 hpa p e < 500 hpa Spike p abs < 300 kpa p abs < 500 kpa Sample cell material Cell tube Aluminum Silica glass (SiO 2 ) Stainless steel (SAE 316Ti) Window CaF 2, adhesive fastening Silica glass CaF 2 or SiO 2, threaded fastening Seal FFKM75 FFKM70 Connectors SS (SAE 316Ti) PFA SS (SAE 316Ti) Gas line materials FPM or PTFE PFA SS (SAE 316Ti) Gas connector materials SS (SAE 316Ti) PFA SS (SAE 316Ti) Sample gas connection design (connection drawings see page 9) Connectors with 1/8 NPT internal threads Pipes 6/4 mm Pipes with 4 mm outer diameter 1) see page 7 Sample gas inlet conditions 2) purge curtain 3) p e = 7 to 20 hpa, 15 to 20 l/h 4) The analyzer module is suitable for measuring flammable gases and vapors under atmospheric conditions (p abs 1.1 bar, oxygen content 21 vol.%). Temperature class: T4. The sample gas must not be explosive under normal conditions. If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation p e 100 hpa; in case of a sample gas supply failure the pressure must not exceed the maximum value p e = 500 hpa. Before using the analyzer module the corrosion resistance against the specific sample gas must be checked. 8 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

9 Process photometer analyzer modules Limas11, Limas11 HW Gas connections Limas11: Standard cell with FPM or PTFE hoses, Quartz cell with FPM hoses, Center connection cell made of aluminum or quartz Limas11: Quartz cell with PFA tubes BUS BUS 4 1 Service 9 Service 24 V DC V DC Sample gas inlet 1 Sample gas inlet 3 Purge gas inlet housing 1) 3 Purge gas inlet housing 1) 4 Sample gas outlet 4 Sample gas outlet 6 Purge gas outlet housing 1) 6 Purge gas outlet housing 1) 7 Pressure sensor 2) 7 Pressure sensor 1) 3) 8 End-point gas inlet (with 3 solenoids) 1) Option 9 Zero-point gas inlet (with 1 or 3 solenoids) 1) 3) 1) Option 2) external connection, not for standard cell with FPM hoses 3) not for version with PTFE hoses Limas11: Safety cell Limas11 HW BUS 4 1 BUS 1 Service 5 2 Service 7 24 V DC VDC Sample gas inlet 1 Sample gas inlet 2 Sample gas outlet 3 Purge gas inlet housing 3 Purge gas inlet housing 1) 4 Sample gas outlet 4 Purge gas inlet sample cell 6 Purge gas outlet housing 5 Purge gas outlet sample cell 7 Pressure sensor 6 Purge gas outlet housing 1) 7 Pressure sensor 1) Option 10/ EN Rev. 6 Advance Optima AO2000 Series Data Sheet 9

10 Process photometer analyzer module Limas11 HW Measurement principle and application Limas11 HW is a multi-component analyzer for simultaneous measurement of nitrogen compounds in wet sulfur-free flue gas without converter. Measurement principle Photometer to measure from 1 to 4 components such as NO, NO 2 and NH 3. Wavelength comparison in ultraviolet spectrum range λ = 200 to 600 nm for sample components NO 2 and NH 3. The UV-RAS method (ultra-violet resonant absorption spectroscopy) is used to make the analyzer selective to the sample component NO. Applications Exhaust gas measurement for the development of combustion engines and methods for exhaust gas after-treatment, in particular for pure gas measurement after catalyst in Four-stroke gasoline and diesel engines, Catalysts for nitrogen oxide reduction. Process measurement for flue gas scrubbing systems in gas turbines and gas-fired burners, in particular for monitoring, controlling and optimizing DeNOx SCR processes. Sample components and measurement ranges (recommendations), stability data Exhaust gas measurement for four-stroke gasoline and diesel engines Sample component Smallest range Largest range NO ppm ppm NO ppm ppm Linearity deviation 1 % of span, 2 % of measured value acc. to EPA specifications for automotive exhaust gas measurement Repeatability 0.25 % of span Zero drift 1 ppm or 1 % of span per 24 hours based on the smallest recommended measurement range (daily automatic zero-point calibration recommended) Sensitivity drift 1 % of measured value per week Output fluctuation (2 σ) 400 ppb or 0.4 % of span at electronic T90 time = 5 sec Detection limit (4 σ) 800 ppb or 0.8 % of span at electronic T90 time = 5 sec Diluted exhaust gas measurement for four-stroke gasoline and diesel engines, bag measurement Sample component Smallest range Largest range NO 0 10 ppm ppm NO ppm ppm Linearity deviation 1 % of span, 2 % of measured value acc. to EPA specifications for automotive exhaust gas measurement Repeatability 0.25 % of span Zero drift 250 ppb or 2 % of span per 8 hours based on the smallest recommended measurement range (daily automatic zero-point calibration recommended) Sensitivity drift 1 % of measured value per week Output fluctuation (2 σ) NO 50 ppb, NO 2 60 ppb at electronic T90 time = 15 sec Detection limit (4 σ) NO 100 ppb or 1 % of span, NO ppb or 1 % of span at electronic T90 time = 15 sec Process measurement Sample Component Smallest Range Largest Range NO ppm ppm NO ppm ppm NH ppm ppm Linearity deviation 1 % of span Repeatability 0.25 % of span Zero drift 1 ppm or 1 % of span per 24 hours based on the smallest recommended measurement range (daily automatic zero-point calibration recommended) Sensitivity drift 1 % of measured value per week Output fluctuation (2 σ) 150 ppb or 0.15 % of span at electronic T90 time = 30 sec Detection limit (4 σ) 300 ppb or 0.3 % of span at electronic T90 time = 30 sec Measurement ranges Quantity 1 to 4 ranges per sample component Measurement range ratio Max. 1:20. Measurement ranges are freely adjustable within a range ratio of 1: 20 relative to the factory-set reference measurement range. Max. 1:50 for fixed measurement ranges acc. to EPA specifications for automotive exhaust gas measurement 10 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

11 Process photometer analyzer module Limas11 HW Influence effects Flow effect Flow rate in the 20 to 90 l/h range: within detection limits Associated gas effect/cross sensitivity The knowledge of the sample gas composition is necessary for the analyzer configuration. Selectivity measures to reduce associated gas effect: Internal electronic cross-sensitivity correction or carrier gas correction for a sample component by other sample components measured with the Limas11 HW. Temperature effect Ambient temperature in permissible range, Sample cell thermostat control to +80 C At zero-point: 2 % of span per 10 C On sensitivity: 2 % of measured value per 10 C Air pressure effect At zero-point: No effect On sensitivity with pressure correction by means of integral pressure sensor: 0.2 % of measured value per 1 % air pressure change The pressure sensor is routed to the outside via a hose. Pressure sensor working range: p abs = 600 to 1250 hpa Power supply effect 24 VDC ± 5 %: 0.2 % of span Dynamic response Warm-up time Approx. 4 hours 90% response time T 90 5 sec for measurement cell length = 260 mm and sample gas flow = 60 l/h with non-linear filter (static/dynamic) = 15/1 sec. Low-pass time constant adjustable from 0 to 30 sec. Calibration Zero-point calibration With inert gas, e.g. nitrogen, or with ambient air that is free of the sample component End-point calibration With gas-filled calibration cells (optional) or with test gas. It is recommended to verify the calibration cell set values once a year. During calibration of a multi-component analyzer, possible cross-sensitivity and/or carrier gas corrections by internal or external measurement components are switched off. Therefore, corrected measurement components should be calibrated only using a test gas consisting of the measurement component and an inert gas like nitrogen. Materials in contact with the sample medium Sample cell Tubing and window: Silica glass, Screw connection: PVDF; Connectors: PTFE Gas lines and connectors Stainless steel (SAE 303), (SAE 316Ti) Housing purge Purge gas Sample component-free air or nitrogen Purge gas flow rate 10 l/h Sample gas inlet conditions Sample gas composition Sulfur-free exhaust gas of combustors, SO 2 concentration < 25 ppm, H 2 O < 20 vol.%, filtered with pore width 0.5 μm Temperature Sample gas dew point 65 C Inlet pressure p e = 2 to 500 hpa. Lower pressures require a sample gas pump and higher pressures require a pressure reducer. Outlet pressure Atmospheric pressure Flow rate 20 to 90 l/h Gas connections See page 9 Notes The analyzer module Limas11 HW can only be mounted in the 19-inch housing. SO 2 influences the NH 3 reading. If the sample gas mixture contains SO 2, the requirement of internal corrections must be scrutinized. When ordering the average water vapor concentration has to be specified. The influence is corrected internally. Sample conditioning system requirements Sample gas feed-in The various applications require the sample gas feed-in to the gas analyzer at temperatures of 150 to 190 C. It is imperative to eliminate condensation and sublimation since NH 3 and NO 2 are easy soluble in water and can result in salification. It is also imperative to prevent condensation of potentially present low-boiling hydrocarbons. Sample gas inlet temperature (on the process side) 150 to 190 C Sample gas filter For NO and NO 2 measurement: Sintered metal; for NH 3 measurement: Ceramics; pore width 0.5 μm Materials in contact with the sample medium PTFE, PVDF or Silicosteel Exhaust gas conditions Outlet pressure = atmospheric pressure, no resistance in the gas outlet. Installation note Route the exhaust gas line declining to allow for condensate drain-off. 10/ EN Rev. 6 Advance Optima AO2000 Series Data Sheet 11

12 Oxygen analyzer module Magnos206 Measurement principle Paramagnetic behavior of oxygen Magnetomechanical analyzer; short 90% response time Sample component and measurement ranges Sample component Oxygen (O 2 ) Smallest measurement range 0 to 0.5 vol.% O 2 Measurement range quantity and limits 4 measurement ranges Measurement ranges are freely adjustable; they are factoryset to 0 to 10/15/25/100 vol.% O 2 or per order. Largest measurement range 0 to 100 vol.% O 2 Measurement ranges within ignition limits cannot be provided. Measurement ranges with suppressed zero-point Max. measurement range suppression 1:100, e.g. 99 to 100 vol.% O 2. Highly suppressed measurement ranges ( 95 to 100 vol.% O 2 ) and initial measurement ranges in the same analyzer should be avoided. Pressure correction by means of pressure sensor required. Stability Linearity deviation 0.5 % of span, minimum vol.% O 2 Repeatability 50 ppm O 2 (time base for gas exchange 5 minutes) Zero drift 3 % of span of the smallest measurement range (per order) per week, minimum 300 ppm O 2 per week; following prolonged transport and storage time the drift can be higher during the first weeks of operation. Sensitivity drift 0.1 vol.% O 2 per week or 1 % of measured value per week (not cumulative), whichever is smaller % of measured value per year, minimum 0.05 vol.% O 2 per year Output fluctuation (2 σ) 25 ppm O 2 at electronic T90 time (static/dynamic) = 3/0 sec Detection limit (4 σ) 50 ppm O 2 at electronic T90 time (static/dynamic) = 3/0 sec Influence effects Flow effect 0.1 vol.% O 2 in permissible range Associated gas effect Data regarding the effect of associated gases can be found in IEC : 2002 Gas analyzers Expression of performance Part 3: Paramagnetic oxygen analyzers. Temperature effect Ambient temperature in permissible range At zero-point: 0.02 vol.% O 2 per 10 C On sensitivity: 0.1 % of measured value per 10 C Thermostat temperature = 64 C Air pressure effect At zero-point: No effect On sensitivity without pressure correction: 1 % of measured value per 1 % air pressure change On sensitivity with pressure correction using integrated pressure sensor (optional): 0.1 % of measured value per 1 % air pressure change; for highly suppressed measurement ranges 0.01 % of measured value per 1 % air pressure change or vol.% O 2 per 1 % air pressure change, whichever is greater. Pressure sensor working range: p abs = 600 to 1250 hpa Power supply effect 24 VDC ± 5 %: 0.4 % of span Position effect Zero-point shift 0.05 vol.% O 2 per 1 deviation from horizontal location. Position has no effect on the hardmounted unit. Dynamic response Warm-up time < 1 hour 90% response time T to 10 sec at a sample gas flow of 90 l/h and electronic T90 time (static/dynamic) = 3/0 sec, gas change from nitrogen to air (applies to an analyzer unit with 1 analyzer module) Calibration Zero-point calibration With oxygen-free process gas or substitute gas End-point calibration With process gas with a known oxygen concentration or a substitute gas such as dried air Single-point calibration For measurement ranges from 0 to 5 vol.% O 2 to 0 to 25 vol.% O 2 : Zero-point calibration with any oxygen concentration, e.g. with nitrogen or ambient air, processed through a cooler or H 2 O absorber. Pressure correction by means of pressure sensor is recommended for single-point calibration with air. Depending on the measurement task involved, the zero- and end-points should be verified periodically (recommendation: once a year). Calibration of measurement ranges with suppressed zero-point Highly suppressed measurement ranges ( 95 to 100 vol.% O 2 ) should only be calibrated with test gases with concentrations in the selected measurement range. Single-point calibration can also be done within a suppressed measurement range. The O 2 concentration of the test gas must lie within the measurement range. 12 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

13 Oxygen analyzer module Magnos206 Materials in contact with the sample medium Analyzer Rust- and acid-resistant steel (SAE 303), glass, platinum, rhodium, epoxy resin; FPM seals, optional: FFKM75 Pressure sensor Silicon gel, plastics, FPM Gas connections The sample cell is connected directly to the gas ports Sample gas inlet conditions Temperature +5 to +50 C The sample gas dew point should be at least 5 C below the ambient temperature throughout the sample gas path. Otherwise a sample gas cooler or condensate trap is required. Water vapor content variations cause volume errors. Inlet pressure p e = 2 to 100 hpa Lower pressures require a sample gas pump and higher pressures require a pressure reducer. Outlet pressure Atmospheric pressure Flow rate 30 to 90 l/h Abrupt changes in gas flow rates should be avoided when using highly suppressed measurement ranges. Corrosive gases Consultation with ABB Analytical is required if the sample gas contains Cl 2, HCl, HF or other corrosive components. FFKM75 seals must be used if the sample gas contains NH 3. In this case the pneumatics module cannot be connected to the analyzer module. Flammable gases The analyzer module is suitable for measuring flammable gases and vapors under atmospheric conditions (p abs 1.1 bar, oxygen content 21 vol.%). Temperature class: T4. The sample gas must not be explosive under normal conditions. If the sample gas is explosive in the event of a sample gas supply failure, then only seldom and briefly (in accordance with zone 2). Pressure in the sample gas path in normal operation p e 100 hpa; in case of a sample gas supply failure the pressure must not exceed the maximum value p e = 500 hpa. Before using the analyzer module the corrosion resistance against the specific sample gas must be checked. Housing purge with nitrogen should be provided when measuring flammable gases and vapors. Flame barriers can be used as an option (except for the safety concept version, see page 34). Pressure drop at the flame barriers approx. 40 hpa for a sample gas flow rate of 50 l/h. Material of the flame barriers: Stainless steel (SAE 316Ti). Version in category 3G see page Sample gas inlet 2 Sample gas outlet 3 Purge gas inlet analyzer 2) 4 Purge gas outlet analyzer 2) 7 Purge gas inlet housing 1) 8 Purge gas outlet housing 1) (also with flow sensor) 9 Pressure sensor 1 1) 10 Pressure sensor 2 1) Pneumatics module 1) : 11 Sample gas inlet 12 End point gas inlet (with 3 solenoids) 13 Test gas/zero-point gas inlet (with 1 or 3 solenoids) 14 Sample gas outlet connect with inlet 1 1) Option 2) not in version with performance test for emission monitoring 10/ EN Rev. 6 Advance Optima AO2000 Series Data Sheet 13

14 Oxygen analyzer module Magnos27 Measurement principle Paramagnetic behavior of oxygen Heavy-duty thermomagnetic analyzer Sample component and measurement ranges Sample component Oxygen (O 2 ) in flue gas or in nitrogen Smallest measurement range 0 to 3 vol.% O 2 Measurement range quantity 1 to 4 measurement ranges Ranges are factory-set per customer order. Largest measurement range 0 to 100 vol.% O 2 Measurement ranges within ignition limits cannot be provided. Stability Linearity deviation 2 % of span Repeatability 1 % of span Zero drift 1 % of span per week Sensitivity drift 2 % of measured value per week Output fluctuation (2 σ) 0.5 % of smallest measurement range span at electronic T90 time = 0 sec Detection limit (4 σ) 1 % of smallest measurement range span at electronic T90 time = 0 sec Influence effects Flow effect 1 % of span at a flow change of ±10 l/h. At an identical flow rate for test and sample gases the flow rate effect is automatically compensated. Associated gas effect Magnos27 calibration applies only to the sample gas shown on the identification plate (= sample component + associated gas). Temperature effect Ambient temperature in permissible range At zero-point: 2 % of span per 10 C On sensitivity: 0.5 % of measured value per 10 C relative to temperature at the time of calibration Thermostat temperature = 63 C Air pressure effect At zero-point: < 0.05 vol.% O 2 per 1 % air pressure change On sensitivity without pressure correction: 1.5 % of measured value per 1 % air pressure change On sensitivity with pressure correction: 0.25 % of measured value per 1 % air pressure change Option: Operating altitude over 2000 m Power supply effect 24 VDC ± 5 %: 0.2 % of span Position effect Approx. 3 % of smallest measurement range span per 1 deviation from horizontal orientation. Position has no effect on the hard-mounted unit. Dynamic response Warm-up time 2 to 4 hours 90% response time T 90 = 10 to 22 sec, depending on sample gas flow and on measurement cell connection (see Gas connections, applies to an analyzer unit with 1 analyzer module) Calibration Zero-point calibration With oxygen-free process gas or substitute gas End-point calibration With process gas having a known oxygen concentration or with substitute gas 14 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

15 Oxygen analyzer module Magnos27 Materials in contact with the sample medium Analyzer Rust- and acid-resistant steel (SAE 316Cb) and (SAE 303), glass Gas lines and connectors Rust- and acid-resistant steel (SAE 316Ti) and (SAE 303), PVC-C, FPM Gas connections Sample cell connection by means of FPM hoses 10 1 Sample gas inlet conditions Temperature +5 to +50 C The sample gas dew point should be at least 5 C below the ambient temperature throughout the sample gas path. Otherwise a sample gas cooler or condensate trap is required. Water vapor content variations cause volume errors. Inlet pressure p e = 2 to 100 hpa Lower pressures require a sample gas pump and higher pressures require a pressure reducer. Outlet pressure Atmospheric pressure Flow rate 20 to 90 l/h Flammable gases Measurement of flammable gases is not possible Sample cell direct connection The sample cell is connected directly to the gas ports (for wallmount housing only). Application e.g. when external gas supply is connected and for short T 90 times Purge gas inlet housing 1) 2 Purge gas outlet housing 1) (also with flow sensor) 3 4 Sample gas inlet 5 Purge gas inlet analyzer 6 Purge gas outlet analyzer 7 Sample gas outlet 8 9 Pressure sensor 1 1) 10 Pressure sensor 2 1) Pneumatics module 2) : 11 Sample gas inlet 12 End point gas inlet (with 3 solenoids) 13 Test gas/zero-point gas inlet (with 1 or 3 solenoids) 14 Sample gas outlet connect with sample gas inlet 4 1) Option 2) Option not in version with sample cell direct connection 10/ EN Rev. 6 Advance Optima AO2000 Series Data Sheet 15

16 Trace oxygen analyzer module ZO23 Measurement principle Potentiometric measurement; zirconium dioxide cell for determination of the oxygen concentration in accordance with Nernst s equation; reference gas: ambient air. The analyzer module is used for the continuous measurement of oxygen in pure gases (N 2, CO 2, Ar). The measuring cell is catalytically inactivated to the extent that flammable carrier components in stoichiometric concentrations only negligibly reduce the oxygen value. Sample component and measurement ranges Sample component Oxygen (O 2 ) Measurement range quantity and limits 4 measurement ranges Measurement ranges are freely adjustable within the 0 to 1 ppm to 0 to 250,000 ppm O 2 range; they are factory-set to 0 to 1/10/100/1000 ppm O 2 The following measurement data refer to a measurement span of 100 ppm O 2 with a regulated flow rate of 8 ± 0.2 l/h. Stability Linearity Owing to the measurement principle, zirconium dioxide cells are base linear. Repeatability < 1 % of the measurement range or 100 ppb O 2 (whichever is greater) Zero drift The zero point (reference point) is displayed if ambient air is present on the sample gas side. The value for air of 20.6 vol.% O 2 (for 25 C and 50 % relative humidity) may deviate through aging of the cell. < 1 % of the measurement range per week or 250 ppb O 2 (whichever is greater) Sensitivity drift Depends on possible interfering components (catalyst poisons) in the sample gas and the aging of the cell. For pure gas measurements in N 2, CO 2 and Ar: < 1 % of the measurement range per week or 250 ppb O 2 (whichever is greater) Output fluctuation (2 σ) < ±0.5 % of the measured value or 50 ppb O 2 (whichever is greater) Detection limit (4 σ) < ±1 % of the measured value or 100 ppb O 2 (whichever is greater) Influence effects Flow effect 300 ppbv O 2 in the permissible range Associated gas effect Inert gases (Ar, CO 2, N 2 ) have no effect. Flammable gases (CO, H 2, CH 4 ) in stoichiometric concentrations to the oxygen content: Conversion of O 2 < 20 % of the stoichiometric conversion. If higher concentrations of flammable gases are present, higher O 2 conversions must be expected. The concentration of flammable gases in the sample gas must not exceed 100 ppm. Temperature effect The effect of the ambient temperature in the permissible range of +5 to +45 C is < 2 % of the measured value or 50 ppb O 2 per 10 C change in the ambient temperature (whichever is greater). Air pressure effect No effect through a change in air pressure; sample gas must flow out of the outlet without back pressure. Power supply effect 24 VDC ± 5 %: no effect Position effect No position effect for permanently installed instruments Dynamic response Warm-up time The operating temperature of the cell is reached after approx. 15 min. Offset calibration with reference gas (ambient air) after 2 h flow. The measurement is ready-to-run after valves and lines have been purged with sample gas. Typical purging time for valves and lines: approx. 2 to 5 h. 90% response time T 90 < 60 s for the alternation of 2 test gases in the measurement range 10 ppm with a sample gas flow rate = 8 l/h and electronic T90 time = 3 s Calibration Offset calibration The reference value for ambient air is calibrated at 20.6 vol.% O 2 by means of ambient air on the sample gas side. End-point calibration By means of test gas O 2 in N 2 (or in CO 2 or Ar); O 2 concentration in the measurement range, e.g. 10 ppm O 2 Function test An extended response time or reduced sensitivity are dimensions for the correct functioning of the measuring cell. The function test can be carried out without any additional test gases by feeding the sample gas with constant concentration. On the basis of the progression of the test, it can be assessed whether the reaction time of the sensor lies within a specified tolerance. The function test is started manually and lasts approx. 15 min. An additional function block configuration is required for a cyclic scan. 16 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

17 Trace oxygen analyzer module ZO23 Materials in contact with the sample medium Analyzer Zirconium dioxide cell: ZrO 2, electrodes containing platinum; Dust filter (option): Flow sensor (option): on semiconductor basis, nickel-plated brass Gas lines and connectors Stainless steel (SAE 316Ti), FPM and silicon hoses in the gas outlet; Gas connections: stainless steel / (SAE 316/SAE 303) Gas connections The measuring chamber is connected to the sample gas inlet connection via a stainless steel tube (inlet side) and to the sample gas outlet connection via a FPM hose (outlet side). Sample gas inlet conditions The analyzer module must not be used for measurement of ignitable gas/air or gas/oxygen mixtures. Temperature +5 to +50 C Inlet pressure p e 70 hpa Outlet pressure Atmospheric pressure Flow rate 4 to 20 l/h. Use a metering valve to set the flow rate. Corrosive gases The presence of corrosive gases and catalyst poisons, e.g. halogens, gases containing sulfur and heavy-metal dust, leads to faster aging and/or destruction of the ZrO 2 cell. Flammable gases The analyzer is suitable for measuring flammable gases in general purpose environment. The concentration of flammable gases in the sample gas must not exceed 100 ppm. Purge gas If case purging is selected, purging may only be carried out with air (not with nitrogen), since the ambient air is used as a reference gas. 1 Sample gas inlet 3 mm Swagelok 2 Sample gas outlet 1/8 NPT internal thread 7 Purge gas inlet housing (only for IP54 version) 8 Purge gas outlet housing (only for IP54 version) Note The trace oxygen analyzer module cannot be connected to the pneumatics module. 10/ EN Rev. 6 Advance Optima AO2000 Series Data Sheet 17

18 Thermal conductivity analyzer module Caldos25 Measurement principle Difference in thermal conductivity of various gases Highly corrosion-resistant thermal conductivity analyzer, sample cells embedded in glass Sample components and measurement ranges The Caldos25 is specifically designed for measurements of corrosive gas components. Sample components and smallest measurement ranges (examples) Component and associated gas Smallest measurement range Reference gas H 2 in N 2 or air vol.% Air (sealed) SO 2 in N 2 or air vol.% Air (sealed) H 2 in Cl vol.% Flowing Measurement range quantity and limits 1 to 4 measurement ranges per sample component Ranges are factory-set per customer order. Largest measurement range 0 to 100 vol.% or 0 vol.% to saturation Measurement ranges within ignition limits cannot be provided. Measurement range switching ratio 1:20 Measurement ranges with suppressed zero-point Span at least 2 vol.%, depending on application Stability Linearity deviation 2 % of span Repeatability 1 % of span Zero drift 1 % of span per week Sensitivity drift 1 % of measured value per week Output fluctuation (2 σ) 0.5 % of smallest measurement range span at electronic T90 time = 0 sec Detection limit (4 σ) 1 % of smallest measurement range span at electronic T90 time = 0 sec Influence effects Flow effect 1 to 5 % of span at a flow change of ±10 l/h. At an identical flow rate for test and sample gases the flow rate effect is automatically compensated. Associated gas effect Analyzer calibration should be based on an analysis of the sample gas. Measurement results can be greatly distorted by interfering components in complex (non-binary) gas mixtures. Temperature effect Ambient temperature in permissible range at each point in the measurement range: 1 % of span per 10 C, based on temperature at the time of calibration Thermostat temperature = 60 C Air pressure effect No effect in permissible operating condition range Power supply effect 24 VDC ± 5 %: 0.2 % of span Position effect < 1 % of span up to 10 deviation from horizontal orientation Dynamic response Warm-up time 1.5 hours 90% response time Typical T 90 = 10 to 20 sec; optional: T 90 < 6 sec (applies to an analyzer unit with 1 analyzer module) Calibration Zero-point calibration With sample component-free process gas or substitute gas End-point calibration With process gas having a known sample gas concentration or with substitute gas 18 Advance Optima AO2000 Series Data Sheet 10/ EN Rev. 6

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